Fiber-glass reinforced percussive tool handle



FIBER-GLASS REINFORCED PERCUSSIVE TOOL HANDLE Filed July `22, 1955 June 14, 1960 J, L CURRy ETAL 2 Sheets-Sheet 2 ,l \\\\\\\\\\\\\\\\\\\\\N im BY www United States Patent Oce I FIBER-GLASS REmroncED PERcUssrVE 'root HANDLE .lohn J. Curry and Robert C. Watson, Philadelphia, Pa., assi'gnors, by direct and mesne assignments, to Fayette R. Plumb, Inc., Philadelphia, Pa., a corporation of Pennsylvania Filed July 2,2, 1955, Ser. No. 523,773

V4 Claims. (Cl. 145-61) The present invention relates in general to hand tools, and more particularly to handles for percussive tools, such as hammers, hatchets, mauls, sledges, axes, picks and the like. The handle construction provided fby the present invention is also applicable to tools other than those included specifically within the class designation of percussive tools, such as those wherein the handles are subject to occasional severe stress requiring high tensile, exural and compressive strength in the tool handle.

Heretofore, it has been the prevalent practice in the triade to construct the handles for percussive tools such as hammers and the like from high grade hickory wood, which inherently has more desirable characteristics, particularlyvstrength and resiliency, in this field than other Woods which are obtainable. The continued use of hickory handles in percussive and other tools has been ustied primarily because of lthe high strength of hickory relative '-to that of other woods, the good dynamic qualities provided in the nal products when hickory handles are incorporated therein, and favorable economics f using this type wood. However, all woods, including hickory, are of obviously limited strength and are therefore subject to breakage under relatively low stresses.

To overcome vthese problems others have explored the use offorgedsteel handles for such tools. Such steel handleslhave been found to provide greater strength than hickory handles. However, -because of the high density offsteel, tools incorporating handles of this type have beenV found to have poor `dynamic qualities as proper location ofthe centers of gravity and percussion cannotflbe obtained other minimum practical design requirements e are'vtolbe met.V

The search for synthetic materials, particularly in the field of plastic compositions, to provide abetter basic material than hickory wood or steel in handles of such percussive tools by which improved physical characteristics may be obtained, has been beset with many diiiiculties.

The demanding requirements of high tensile'fand flexural ,l strength in the eye and throat regions of the percussion i tool handle, high compressive strength -in the gripregion; ofthe handle, and high impact resistance throughout the handle'require that any plastic composition employed inv handles for percussive toolsbetreinforced, asfthe flexural strengthcharacteristics of `unreinfoi'ced plastics are'not suitableto the conditions encountered inthe use of percussive, tools.

Y enl lolyester-type resins reinforced by glass fibers having considerably lower density than steel, which have heretofore been employed commercially in the productionv of so-called fiber-glass reinforced plasticy products such as fishing rods, and the like, as a substitute for steel and` bamboo, and ywhich Ain such commercial applications possessed satisfactory physical strength characteristics, are available asa possible improved basic-material for handles v However, resort to such a composi` 'tion to produce a handle for such tools having the qualiof percussion tools.

ties co sidered to be necessary for a satisfactory percuschopped strands, fiber-glass roving which is a continuous f filament of a preselected number of ends of glass bers which are unidirectional vwith their axes all located parallel to each other `and to the principal axis of the roving, ber'- glass matt which is formed of a strata of omnidirectional chopped strandsbound together chemically, and woven cloth formed of glass fibers extending along perpendicular axes.

Tests have revealed that continuous glass fiber longitudinally oriented provide the flexural strength characteristics necessary for percussive tool handles. The use of unoriented chopped strands of fibrous glass alone as the reinforcing medium has been found to be unsatisfactory .as this form of reinforcing does not produce the high tensile and compressive strength characteristics required lfor the type of loading found in such tools. The fiberglass mat and Woven fiber-glass cloth are unsuitable as reinforcing media in such applications.

The selection of a fiber-glass reinforced plastic material which will -be suitable for handles of percussive tools poses serious problems insofar as the achievement of the desired strength and dynamic qualities of the handle are concemed. The material employed for such handles must permit variation in cross section along the axis of the handle without'disturbing the continuity of the fibers, or the flexural strength of the handle is reduced to a point where the handle cannot withstand the cantilever loading conditions encountered in normal use. Since solely longitudinally oriented fibers have little compressive strength in the direction of the axis of the handle, provision must be made for high'impact strength in the handle butt section, since the butt of the hammer or other percussive tool would be frequently used for driving boards and the like, and since the handle must be protected against fracture when the tool isdropped. High compressive strength transverse to the longitudinal axis of the handle must y the tool is in use. This is essential to the provision of a percussive tool which has the proper dynamic qualities and heft to permit effective and eicient use. Additionally, the shock dampeninglqualites of the ber-glass reinforced plastic material'must be adequate to prevent unpleasant transfer ofshock to the'lhand of the user.

An object of the present invention, provision of aY novel, reinforced plastic -tool handleV having suitable characteristics for percussion tool applications. Y i i Another object of the present invention is the provision of a fiber-glass Vreinforced molded resin percussion tool Y handle having a high tensile and exural strength region, a high compression strength region, and a highly impactresistant region, giving the'handle appropriate characteristics for percussion tool uses,

Another object ofthe present invention is the provision of a fiber-glass reinforced polyester-type resin molded handle for percussion 'tools and the like wherein tiberglass roving is embedded in the molded handle in a preselected orientation relative to the longitudinal axis of Patented June 14, 1960 therefore, is the Vtlie-handle to provide high flexural strength characteristics.

Another object of the present invention is the provision offa nve'l'method o'fmolding ber-glass reinforced` polyester-typeyresin handle lfor percussion tools yand the ,likey having' unidirectional berfglass rovingibers uniformly.l

'Y embedded therein in parallelism witlrthe longitudinal axis Vof the' handle, 'whereby Ythe bers are maintained essentiallysuniforrnlyY distributed andunidirectionally `oriented when the-.freinforced resincornpositionbecomes fluid underatherapplicationof heat and Vpressure in Ia mold.

fnoth'er object Yof thelpresentinvention isrthe provision offamove'l method. of compression molding berglass reinforced? Ypolyester-type. resin handles for percussion tools Ythe like wherein-the ber .orientation is maintainedY essentially unidirectionalA and` resin-rich areas in the molded product are avoided.

Other-objects, advantages and capabilities `of the VpresentA invention will become-apparent from the following4 detailed description, taken in conjunction with the accompanying drawing showing only one preferred embodiment ofthe invention.

inthe-drawings:

Figure lis an exploded perspective view of the sections ofrher-glassroving'which are associated together to form.l the major portionof the mold charge in the production of va percussiontool handle in accordance with the present invention;

Figure 2 is a perspective view illustrating the manner in-which the roving sections; are associated together;

Figure 3 isa transverse section view taken along the line ir-S of Figure 2; l

Y'l-igure'i isa top plan view of the assembled preform components of br-glass-Y impregnated resin making up the complete moldchargein the production of one form ofi the present inventionj and,

Eigure 5Y a top plan View of a'molded percussion tool handle "embodying the presentV invention,`with parts of theihandle shown in longitudinal section. f

'Theinvention' will now be describedein detail n'connectiojiwith'y the proqirlctiorrofy a ber-glass reinforced re's-in handle Vfor hammers. VThepreform or charge which As illustrated in Figures 1 and 2, two l1%inch,seg. ments of attened roving, indicated bythe reference characters 10 and 11, and oneVV 6-inch segment .12 of attened roving comprise the elements of a mold preform 13 of this material. l The-rst, step in assembling the preform is to roll the -inch'segment 12 ofthe attened ber-glass roving into a vcylindroid 14 aslindicated in Figures 2 and 3. This cylindroid 144 is then encased by Wrapping the two-Il Mi-inch segments 10 and 11 around it in such a manner that the longitudinal-marginal edgesorf-the segments 10 andV V11 overlap and oomplet'ely'surround the cylindroid 14 except for an approximately 3t-inch portion 15 of the inner cylindroidrwhchlprotrudes from one -endfof the'preform assembly. Yentire preform assembly 13'thu's formed by lthe'Hcylindroid'14 and encasing roving segments 10 and 11V is then' compressed and shaped manually so as to satisfactorily integrate its various components. Y Y VAsi-an.alternative.arrangement, an insert of balsa wood or other compatible material of low specicfweight` maybe substituted for. the cylindroid 14 and encased` between.r the roving segments 10Yand 11, if desired,V without mate,-N rially altering the'Y strength and dynamic qualities of the nished article.

By this arrangement, the parallel unidirectional glass bersin the flattened roving `sections 10,'11 and Haarel maintained in parallelism with each other and withthe longitudinal axis of the tool handle in themoldV preform= so as to maintain the ber orientation in the properdirectionto insure the presence of the required high ex'uralf strengthl characteristics and ability to withstand cantilevery loading inthe nished tool.V Y Y f Y Y Before the mold'is chargedwith the preform 13, there is added tothe'rend of the preform'ljhaving the /finch l.

' projection ofthe inner cylindroid 14 'arnrass constituting` in -the preferred embodiment; approximately 52 grams of a special semiilexible reinforced resin mix; indicated* isto be plaedin the mold and subjectedlto heat and pressure to Y-produpethe molded -handlefisprodlrlcerd fromV twiityp'esof'material. The presence vof the `desired ex- Y 'uralstengthVA characteristics in the nal'molded article is apioductof 4the striotadherence to the hereafter de-V scribed` preparation and molding procedures for main- Y tanni 'the required ber 'orientation during the molding .stage *f e f-Thefmajor portion of themold preform is formed 'froinlacontinuous lengtlr of Ya suitable number ofends, preferably 60,`66Hor`72, of roving type, unidirectional andepafrallel glass bersror vfilaments.`

The roving of continuous glass bers is pulled throughy a .bath 'ofa styrenated,` rigidfthermpsetting polyester. resin to which has beenadded one( percent by weight` of aV catalyst such Vas'b'evnzoyl peroxide anda suitablecoloring agent to impartp'the desired coloritogthevprioduct, the glass bers being thoroughly coated"with thisresin a small amount the vorder opf5`% ofla suitable flexible anda .glass resinratio'vof approximately 50 percent. The c'oatedgrovngoglass bers is ttheir attenedfn vany de srsdfmanner topatten therovinaltn awdth, Ofen-L prxmately 2% kinches and the flattened continuousrovfins. is.; minimo, sentidas .11% :indre.llotlsand 6 inches long', respectively.

generally byfthe reference character 1 6. This semirigid Y' reinforced'resin 16 is Lformed froma lengthoffa-lj suitable number of ends,l generally l2y ends, ofroving-f` type, continuous glass bers or iilaments which arepcoated Vby drawing the sameY through a bath'ofa mixturei of styrenateclY polyesterY resins; consistingf in -the preferred?? embodirnentoftwo parts of rigidfresin 'and' one'part'pfiA exible resin to whichghasY beenladdedonevpercent by weight'of a catalyst s'u'chlas benzoylperoxide 4andla suit? able coloring( agent.;v The coated glassY bers are theu'ffL chopped toaapproximately 3winch lengths in the preferred emlzodiment.in suchV aqfmauner` that the disposition.Q13A thedibers throughout.V thek massof the combination-Loin semirigidjresin and glass bers can be,Y considered: omnidiretional; VThe glass'rre'sinratio of thismasslr ofireinforced resin isfalso approximatelySOpercent. g

reinforced resin isY then compressed' andi shaped;

- prgtilberance l'forms a positioning and interlockingljointY Y Withuthe overlapping chopped'ber resin mixV 1,6.` Y

G0Y Y Y.Toimprove;tlllefsurface characteristics ,of .thewmoldedu.. vproduct and minimize checking'in the surface'thereof,"

In the preferred embodiment, the".lminghfeglentaf 10jand+11 of jlattenedv berfglass roving and 'thev/sinch'j potrusionVV 15 "of the onefend ofthe segments landll prnduce a' preformed" Y Componentgapproximatng 12. in'ches Vi171 length whichgzwith.

, lfmoldland produces'v'a handle approximately'12%11l rigidQresinLyyields a finally composed preform whichgiills' Yseither;'before `Crafter themas, 1s orv cnoppedg'lss;

bers andsemirigid resin is applied totheendof the moldfY Vpreferiti*13, the preform 13,.V in the;form illustrated` inl Y Figure` 2 orwithfthermass 16fappliedfthereto,,mayl bei.Y

coatndorvdusted withathin surface` layer or stratum of:v glass bers milledvtoa/short length of]appr'o'xiinatelyl' l inch applied as byrollingthel preform'in surfacec amer cylindmid 144 projecting-if: omv

number of ends used in both the rovinglforming the segments 10, 11 and 12 and Yof the roving formed into the mass 16 of chopped bers andsemingid resin canbe readily varied, so long as the glass resin ratio is 'main-'j tained at approximately the preferred percentageszhereinbefore enumerated and sucient over-all preform bulk is provided to insure adequate lling of the mold cavity. The glass resin ratio can, of course, be adjusted in Vsuch alternative situations by making suitable variationsin the size of the orifice, through which the resin-loaded glass bers are pulled to strip oi excess resin. v i

From a practical standpoint, it is highly desirable that the particular polyester resins with which the glass bers forming the segments 10, 11 and 12 and the chopped ber mass 16 are formed, be selected from those commercially available resins which will produce reasonably non-tacky and dry masses for ease of handling during the preform preparation and molding operation.

To mold the hammer handle, a two-piece compression mold of the positive type consisting of a force and cavity with appropriate impressions is utilized. As previously described, the 52-gram mass 16 of chopped bers and semirigid resin are manually formed about the protuberance 15 projecting 'om the preform 13 by the mold operator and the thus completed preform is then charged into the mold. The mold is heated by conventional means to a predetermined temperature, and is then closed under the conditions of pressure and time required by the characteristics of the materials making up the preform mold charge to permit shaping of the molded part and proper resin curing. The mold is then opened and the nished part is ejected from the mold by known means.

A positive type compression mold is preferred wherein the force is complementary to the cavity and the recessed molding face has inwardly inclined marginal Walls to bulk the preform into the cavity chamber with minimum displacement of the mold charge between the vertical, parallel side walls of the force and cavity. This insures minimum disturbance of ber orientation during molding and prevents floating of bers away from the points of pressure. Wetting out of the reinforcing medium is improved and waste and scrap are minimized.

Compression molding with ash molds might be employed with a slight reduction in the excellence of the molded product, due to a greater displacement of bers into the ashing which must be removed to produce a properly nished product, thereby rendering discontinuous the bers having portions which floated into the ashing and diminishing the exural strength of the product. Injection, transfer or plunger molding of any such glass fiber reinforced compositions to produce a tool handle by conventional molding techniques are unsatisfactory as a fracturing of the bers takes place in connection with these molding techniques.

By forming the mold charge in the manner herein described, the glass bers in the eye section 18, the throat section 19, and the grip section 20 of the handle are maintained unidirectionally oriented throughout the period when the resin composition is in a uid state in the mold while heat and pressure are applied thereto, thereby retaining the bers in approximate parallelism with the longitudinal axis of the handle. This orientation of the reinforcing glass bers insures maximum exural strength when the tool handle is subjected to the severe cantilevertype loading which occurs during use, for example when a nail is being extracted by means of the hammer claw.

In the above-described manner, a handle for percussive tools may be molded from fiber-glass reinforced plastic` resinswherein a longitudinal variation inthe cross sec.

tion of the product may be achieved without disturbing the continuity of the reinforcing bers, and 4the necessary` flexural strength is preserved.' This arrangement also providesrsuicient compressivestrength perpendicular to the longitudinalaxis ofthe toolfhandle to prevent fracturf'sv of the tool handle under substantially YVall'ljoadswhich= might be anticipated in connectionwith use of such tools.

,The low rdensity. ofgthe, glass jber land resin mix permits the realization "of `a` tool;y handle, vparticularly for; hammersrwherein' thecenter of gravity ofl the' assembled toolf maybe disposed Vin, such 'a location vin the throat region nearthe toolhe'ad as 'tonpla'eethe center of percussion the'striking face'of the tool head.V rl'he,

inherent VVcharacteristics of thisjcompositionprovide theY desired shock dampenin'gqualities for such tools. VThis composition, therefore, permits the incorporation in such tools of substantially all the desirable dynamic qualitiesI formerly associated with hickory handles.

The reinforced mass of part-exible and part-rigid-type resin 16 having embedded chopped glass bers ltherein is to provide the desired high impact resistance characteristics in hammer handles so as to afford maximum resistance to breakage in the event that the hammer and handle assembly should fall from an elevation in a manner that the handle butt is initially struck upon impact or in the event the handle assembly is subject to some similar type impact in this region.

The advantageous characteristics of high flexural strength, including high tensile strength in the eye and throat portions 18 and 19, high compressive strength in the grip region 20 and high impact resistance in the butt portion of the handle produced by the orientation and association of the reinforcing glass bers in the manner hereinabove described, also render this construction of reinforced plastic handles appropriate for the wood or steel handles in other types of percussive tools such as axes, sledges, picks, mauls, and like tool falling within this class designation.

While only one preferred embodiment of the invention has been particularly shown and described, it is apparent that other various modifications may be lmade in the invention without departing from the spirit` and scope thereof, and it is desired, therefore, that only such limitations shall be placed thereon as are imposed by the prior art and are set forth in the appended claims.

We claim:

``l. An elongated handle for hammers and like percussive tools molded into an integral body of varying cross section longitudinally thereof in a compression mold under heat and pressure and having an end portion adapted to be inserted into a tool head eye, a throat portion, a. grip portion, and a butt portion remote from said end portion, said portions being aligned longitudinally of the handle, said end, throat and grip portions consisting of a substantially rigid thermosetting polyester resin reinforced with glass ber roving having the bers thereof all oriented substantially parallel to the longitudinal axis of the handle, and said butt portion being formed of a mass of a mixture of rigid and exible thermosetting polyester resins reinforced with omnidirectional short glass bers distributed substantially uniformly throughout said mass.

2. An elongated handle for hammers and like percussive tools molded into an integral body of varying cross section longitudinally thereof in a compression mold under'heat and pressure and having an end portion adapted to be inserted into a tool head eye, a throat portion, a grip portion, and a butt portion remote from saidend portion, said portions being aligned longitudinally of the handle, said end, throat and grip portions consisting of a substantially rigid thermosetting polyester resin reinforced with glass ber roving having the bers thereof all oriented substantially parallel to the longitudinal axis of the handle to provide high flexural strength including Y hji'gfli Qmpressvestrength. in saidgrip portiomandaid thelpandlgsaidend; throatV andi grip porfioqsfconsisting f W forced with omidirection'al short glass' fibers distributed substantially uniformly 'throughout Ysaidrmass.

Y '4L'fe1ngated'hand1e for hammers and like percussi ve"toro1s which is an integral body having an end'portion fA UNLT'D STTESYPATENTYS $76,413.

. Frederick` f.

Miuspaugh e Ian. 10,111'888 

